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研究生：	賴柏璋 Lai, Po-Chang
論文名稱：	多能工導入成效之研究—以變壓器製造為例 A Study on the Adoption of Multi-skilled Worker Policy—Case of Transformer Manufacturing
指導教授：	楊大和 Yang, Ta-ho
學位類別：	碩士 Master
系所名稱：	工學院 - 智慧製造國際碩士學位學程 International Master Program on Intelligent Manufacturing
論文出版年：	2023
畢業學年度：	111
語文別：	英文
論文頁數：	64
中文關鍵詞：	粗略產能規劃、多能工、工作負荷平衡、混合整數規劃
外文關鍵詞：	Rough-cut capacity planning, Multi-skilled Worker, Workload balancing, Mixed-integer linear programming
相關次數：	點閱：81 下載：13
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多能工作為生產管理經典的研究議題，除了物料規劃、需求管理及生產現場如何分配與安排，企業執行一個好的產能規劃必須搭配多能工進行有效率的生產，在高度客製化的商品中保有市場競爭力，這也促使多年來產官學界對產能規劃議題之研究蓬勃發展，以因應當代需求多變、產品複雜化等產業環境與銷售型態。產能規劃涵蓋內容甚多，其中粗略產能規劃(Rough-cut capacity planning, RCCP)主要針對企業接收到的新訂單做負荷規劃，不僅可以幫助管理者進行資源分配，也可以輔助其快速做出相對應的決策。
本研究以一家變壓器製造商為案例對象，內容主要包含兩大部分。其一，善用該公司既有的資訊架構與數據，建置人員技能評估系統。相較於傳統的產能規劃議題，本研究特色為規劃時便將員工技能納入現場訂單工作的考量，因現場狀況通常是作業人員的工作負荷失衡，部分人員負擔過重，部分人員閒置，資源本身並未妥善利用，故本研究將提出改善，同時也包含如工時計算、生產線平衡等，跟以往既定平台或商業軟體之限制相比較為彈性；其二，針對現場人員進行負荷分配，根據其本身掌握的技能給予調整，並使用現況與另一情境實驗進一步分析改善情況與原因。
實證研究中，實際建構出符合產業客製化需求的人員技能評估系統，就績效而言，安排今日生產訂單所花費的時間提高89%的效益；就線平衡率而言，由原先的25%提高至45%，改善成效達20%；技能利用率則是從42%變成70%，將技能利用率提高28%。

The study of production management is a classic research topic that encompasses various aspects. In addition to material planning, demand management, and how to allocate and arrange production on the shop floor, companies need to implement effective capacity planning in order to maintain market competitiveness in highly customized products. This has led to the flourishing development of research in the field of capacity planning by industry, government, and academia over the years, in response to the ever-changing demands, product complexity, and sales patterns in the industry. Capacity planning covers a wide range of content, and one of its main components is Rough-Cut Capacity Planning (RCCP), which primarily focuses on load planning for new orders received by the company. RCCP not only assists managers in resource allocation but also facilitates them in making corresponding decisions quickly.
This research focuses on a case study of a transformer manufacturer and consists of two main parts. Firstly, it involves leveraging the existing information structure and data of the company to establish a personnel skills assessment system. Unlike traditional capacity planning approaches, this study emphasizes incorporating employee skills into the consideration of on-site order skills. Since the workload of operational staff is often unbalanced, with some shouldering excessive burdens while others remain idle, the resources are not properly utilized. Therefore, this research aims to propose improvements, including factors such as processing time calculation and production line balancing. Compared to established platforms or commercial software, this approach offers more flexibility.
The second part involves load distribution among on-site personnel, adjusting it based on their skills. The study also conducts situational experiments to analyze and improve the current conditions, as well as to identify the underlying reasons for any issues.
In the empirical study, a personnel skills assessment system that aligns with the customized demands of the industry was successfully constructed. In terms of performance, the time required to allocate today's production orders improved by 89%. Regarding line balancing, the rate increased from the initial 25% to 45%, resulting in a 20% improvement. Furthermore, the skill utilization rate increased from 42% to 70%, marking a 28% enhancement in skill utilization.

Table of Contents	vii
List of Tables	ix
List of Figures	xi
1.	Introduction	1
1.1 Research Background	1
1.2 Research Purpose	3
1.3 Research Process	3
1.4 Research Structure	4
2.	Literature Review	5
2.1 Manufacture Resource Planning	5
2.1.1 Rough Cut Capacity Planning	6
2.2 Multifunctional Workers	12
2.3 Assembly Line Balancing	12
3.	Methodology	17
3.1 Standard Processing Time	17
3.2 RCCP Routing Method	17
3.3 Employee Skills Assessment Table	20
3.4 Personnel Skills Assessment System	21
3.5 Line Balancing	22
4.	Case Analysis	25
4.1 Industrial Background of the Company	25
4.2 Company Brief Introduction and Formulation of a Hypothesis	25
4.3 Employee Skills Assessment System	28
4.3.1 Establishing Standard Processing Time	28
4.3.2 Creating a Multi-skilled Worker Database	33
4.3.3 Developing an Employee Skills Assessment System	35
4.3.4 Creating an Integer Programming Mathematical Model	37
4.3.5 Constructing a Personnel Allocation Plan	40
4.4 Selecting Products	41
4.5 Executing the Employee Skills Assessment System	43
4.6 Performance Evaluation	51
4.7 Key Skills	51
5.	Conclusion and Recommendation	59
5.1 Conclusion	59
5.2 Future Prospects and Recommendation	59
References	61
Appendix A. Multiskilled Operators Sheet	63
Appendix A. Multiskilled Operators Sheet (con.)	64

 
List of Tables
Table 2.1 CPOF production information	9
Table 2.2 CPOF workstation capacity	9
Table 2.3 Production routing	10
Table 2.4 Workstation Capacity Requirements	10
Table 2.5 Resource capacity of a P1 product	11
Table 2.6 Workstation demand using resource profiles	11
Table 2.7 Possible assembly line balancing problems	13
Table 3.1 Processing time at each workstation	18
Table 3.2 Volume of demand products in a given month	18
Table 3.3 Total time in a given month at each workstation	18
Table 3.4 Total time in a given month at each workstation (example)	19
Table 3.5 Volume of demand products in a given month (example)	19
Table 3.6 Total time in a given month at each workstation (example)	19
Table 3.7 Job training plan sheet	20
Table 3.8 skill list	24
Table 3.9 Calculations of the mathematical models	24
Table 4.1 Product types	26
Table 4.2 Product code indication	26
Table 4.3 Skill sheet	27
Table 4.4 Current staffing plan	27
Table 4.5 Standard processing time for each production skill	29
Table 4.6 Standard processing time for each production skill (con.)	30
Table 4.7 Today’s order	31
Table 4.8 Total operating time: winding unit	31
Table 4.9 Total operating time: iron core unit	32
Table 4.10 Total operating time: assembly unit	32
Table 4.11 Total operating time: iron box unit	33
Table 4.12 Processing time of each product	35
Table 4.13 Statistics of product types and quantities	41
Table 4.14 Statistics of F1 products and quantities	41
Table 4.15 Statistics of F2 products and quantities	42
Table 4.16 Statistics of F3 products and quantities	42
Table 4.17 Statistics of F4 products and quantities	43
Table 4.18 Statistics of F9 products and quantities	43
Table 4.19 Statistics of FLC products and quantities	43
Table 4.20 Results comparison	51
Table 4.21 Results before and after improvement	53
Table 4.22 Number of people	55
Table 4.23 Utilization rates of the skills and multiskilled operators	56
Table 4.24 Distinguishing the key skills from utilization rates	57
Table 4.25 Number of times each skill is deleted	58

 
List of Figures
Figure 1.1 Output value and annual growth rate of the electrical equipment industry	1
Figure 1.2 Research process	4
Figure 2.1 MRP II structure	6
Figure 2.2 RCCP on production volumes	8
Figure 4.1 Multiskilled worker database	34
Figure 4.2 Employee skills assessment	36
Figure 4.3 Source code-1	37
Figure 4.4 Source code-2	38
Figure 4.5 Source code-3	38
Figure 4.6 Total time each skill takes	39
Figure 4.7 Multiskilled worker data	39
Figure 4.8 Result-1	40
Figure 4.9 Result-2	40
Figure 4.10 Employee skills assessment system with order details	44
Figure 4.11 Standard processing time table	45
Figure 4.12 Total time	46
Figure 4.13 Total time each skill is used	47
Figure 4.14 Integer programming solver	48
Figure 4.15 Results of the integer programming model	49
Figure 4.16 Results shown in the notepad	49
Figure 4.17 Importing text into the system	50
Figure 4.18 Original staff workload plan	51
Figure 4.19 Adjusted staff workload plan	52
Figur 4.20 Key skill results	54
                                    

楊光正（2022），電力設備及配備製造業110年產值創歷史新高，產業經濟統計簡訊，https://www.moea.gov.tw/Mns/dos/bulletin/Bulletin.aspx?kind=9&html=1&menu_id=18808 （取得日期：2022年4月20日）
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